A Practical Guide To Improving Steel Manufacturing Processes and Production Methods

A practical guide to improving steel manufacturing
processes and production methods

Table of Contents
Overview Technology
Manufacture clean steel that meets the most stringent PGNAA and PFTNA technology...................................... 15
customer requirements.......................................................... 04 X-ray fluorescence (XRF).................................................. 16
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The metals making process................................................. 05 Near-infrared (NIR) spectroscopy.................................... 18
Quality and efficiency opportunities................................... 06 Optical emission spectrometry (OES)............................ 19
Verifying materials....................................................................07
Analyzing scrap....................................................................... 08 Equipment
Feeding process materials.................................................... 09 An overview of products available for the steel
Metal gauging...........................................................................10 making process.................................................................... 21
Energy efficiency......................................................................11 Products for monitoring raw materials in steel............ 22
Environmental (air & radiation)............................................. 12 Products for analyzing trace metals and alloying
Microalloyed and low carbon steel elements.................................................................................... 23
considerations....................................................................... 13 Gauging products for hot and cold rolling
processes................................................................................. 24
Improving furnace efficiency and reducing energy
consumption.......................................................................... 26
Environmental - Air quality monitoring............................ 27
Environmental - Radiation monitoring and soil
analysis................................................................................... 28
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Overview
Manufacture clean steel that meets the most
stringent customer requirements
The steel industry faces increasing demand for clean and
ultraclean steel with improved mechanical properties. With

efficiency and sustainability in mind, steel producers also
strive to produce quality strip in a manner that maximizes mill
yield and minimizes scrap while meeting stringent customer
specifications for thickness, width, hardness, and strength.
Whether you’re producing steel from iron ore or scrap, and
your end product is several inch-thick slabs or galvanized
sheet less than a millimeter thick, the following pages introduce
technologies that will help improve each stage of the steel
manufacturing production process, from incoming raw materials
to the final coating line.

The metals making process
Steel process map

Quality and efficiency opportunities
Feeding
Verifying Analyzing Metal Energy Environmental
process
materials scrap gauging efficiency air & radiation

materials

Verifying materials
Analyzing and verifying your materials –
from beginning to end
Steel manufacturing facilities meet quality standards by utilizing

both handheld X-ray fluorescence instruments and OES metal
analyzers for examination of raw materials, slag, trace and
alloying elements throughout production.
Demanding steel plants, pure metals producers and companies

needing the best determination of all the elements turn to
the Optical Emission Spectrometers for high accuracy analysis
of iron and steel from trace to alloying element levels.
Online PGNAA elemental analyzers are used in the sinter

feed application as chemical composition is one of the most
important parameters for the efficiency of the sinter process.
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steel raw material processing.

Analyzing scrap
Using scrap metal as a raw material
Manufacturing steel from scrap yields energy and green-house
emissions savings. However, the addition of scrap into the steel

production line is a major challenge for the industry.
Compared to the clean raw material to which manufacturers

are accustomed, post-consumer scrap is composed of an
unknown mixture of metals, alloys, and grades. It may be
contaminated by radioactive sources or other hazardous
elements.
With product quality, process integrity, safety, and regulatory

compliance at risk, steel producers can rely on handheld
x-ray fluorescence (XRF) analyzers to know the exact grade
and composition of the scrap material being introduced into
the process. Radiation monitoring portals, personal radiation
detectors, and Geiger counters should be utilized before and
after the scrap enters the facility.

Feeding process materials
Raw materials quality control
Precise feeding of process materials is critical to maintaining
product quality, but measuring and ensuring steel raw material

quality control can be challenging.
• Steel mills need belt scales with a range of conveyor speeds and
levels of accuracy.
• Weighbelt feeders provide a consistent flow for blending or batching,

from light materials at low feed rates to heavy-duty loads requiring
faster feeds.
• Online elemental analyzers help monitor and control sintering process

fluctuations, inhomogeneous mixtures, and other parameters that
affect productivity, physical and metallurgical quality, and raw material
consumption and costs.

Metal gauging
Gauging metal thickness and weight
Metal thickness and coating weight gauges are used in both
hot strip and cold-rolling mills. Gauging equipment provides

precise, real-time measurements during high-speed production
of steel plate and sheet to help you meet the tightest tolerances
while maximizing raw material use.
There are coating weight gauges to ensure coating uniformity

and product quality, thickness gauges to help increase
productivity, and profile gauges to help produce thinner,
stronger steels – which also allow in-bar correction of off-gauge
product, resulting in raw materials savings and mill optimization.
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metal thickness and coating weight gauges.

Energy efficiency
Furnace efficiency and energy
consumption
Process mass spectrometers are widely used

in many important gas analysis applications in
iron and steel plants, including blast furnace,
basic oxygen steelmaking, coke oven gas
analysis, secondary steel process control,
fuel gas analysis and direct reduction of iron
making processes in order to improve furnace
efficiency, reduce energy consumption, and
maintain compliance with ambient air quality
monitoring and reporting requirements.

Environmental (air & radiation)
Furnace efficiency and energy consumption
Continuous emissions monitoring systems (CEMS)
Comply with regulatory guidelines while meeting your own specific

air quality monitoring needs. Thermo Scientific Continuous
Emissions Monitoring Systems (CEMS) are designed to meet
US EPA 40CFR Parts 60 and 75 standards while providing
unsurpassed sensitivity, accuracy and reliability.
Radiation detection portals & monitors

Detect illicit nuclear materials inside packages or cargo at
airports, seaports, borders, government buildings, food
storage and handling facilities, transportation stations, couriers
and freight companies with radiation monitoring devices.

Microalloyed and low carbon steel
considerations
Microalloyed steels, or High Strength Low-Alloy steels (HSLA), are strengthened by adding
“micro” alloy concentrations to low-carbon mild steel.

Low-carbon steel is used to make clutch housings, bushings and suspension components
such as brackets and control arms. Because it improves weldability, low carbon steel is also
used in decorative applications such as automotive wheel covers, and as fasteners such as
nuts, bolts, screws and washers.
Analysis of microalloying elements in steel Improving Low Carbon Steel Production in Specialty
Some handheld XRF analyzes provide excellent trace and Steel Processes
micro element precision and sensitivity for microalloyed steel While much of the world’s steel is still produced in primary
analysis. Given appropriate sample preparation, the analyzer steel processes, the need for steel with greater durability and
is able to quickly and reliably verify whether the levels of corrosion resistance has led to the increased use of vacuum
microalloying elements are in agreement with the mill test degassing processes. Fast and continuous gas analysis of
report and meet the chemical composition requirements per the furnace exhaust gas by process mass spectrometers is
specification. important to secondary steel production.

Technology
PGNAA and PFTNA technology
Prompt gamma neutron activation analysis and pulsed fast thermal neutron activation are based
on a subatomic reaction between a low energy neutron and the nucleus of an atom. When a
thermal, or rather low energy neutron (<0.025 eV) approaches near enough to, or collides with,

a nucleus of an atom, an interaction between the neutron and the nucleus takes place. Energy
from the neutron is transferred to the nucleus and temporarily elevates it to an excited energy
state. The energy is then released, nearly instantaneously, in the form of a gamma ray. The
gamma-ray given off has a distinct energy associated with the atom from which it was released.
In essence the gamma-ray emitted is like a “fingerprint” of the element. The emitted gamma-
rays are detected and an energy spectrum generated which can then be analyzed for elemental
composition.
Click here to learn more about PGNAA and PFTNA.

X-ray fluorescence (XRF)
XRF (X-ray fluorescence) is a non-destructive analytical technique used to determine the
elemental composition of materials. XRF analyzers determine the chemistry of a sample by
measuring the fluorescent (or secondary) X-ray emitted from a sample when it is excited

by a primary X-ray source. Each of the elements present in a sample produces a set of
characteristic fluorescent X-rays (“a fingerprint”) that is unique for that specific element, which
is why XRF spectroscopy is an excellent technology for qualitative and quantitative analysis of
material composition.
The X-ray fluorescence process
• A solid or a liquid sample is irradiated with high energy X-rays from a controlled X-ray tube.
• When an atom in the sample is struck with an X-ray of sufficient energy (greater than the atom’s K or
L shell binding energy), an electron from one of the atom’s inner orbital shells is dislodged.
• The atom regains stability, filling the vacancy left in the inner orbital shell with an electron from one of
the atom’s higher energy orbital shells.
• The electron drops to the lower energy state by releasing a fluorescent X-ray. The energy of this
X-ray is equal to the specific difference in energy between two quantum states of the electron. The
measurement of this energy is the basis of XRF analysis.
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XRF Technology in the Field

X-ray fluorescence (XRF)

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XRF Technology in the Lab

Near-infrared (NIR) spectroscopy
A spectroscopic method that uses the near-infrared region of the electromagnetic spectrum,
and is based on overtones and combinations of bond vibrations in molecules.

Click here to learn more about NIR Spectroscopy

Optical emission spectrometry (OES)
OES enables you to perform rapid elemental analysis of solid metallic samples with optical
emission spectrometry using Arc/Spark excitation. This technique meets the most demanding
analysis needs of the metals industry from production control to R&D, from incoming material

inspection to scrap sorting.
Read how OES provides

ultra-fast methods allowing
characterization of inclusion
during steel production.

Equipment
An overview of products available for the
steel making process

Click here to download the infographic:
The Iron and Steel Manufacturing Process.

Products for monitoring raw materials in steel

CB Omni Fusion Online Ramsey Conveyor Belt Ramsey Weighbelt MOLA/MOLA-LS (Limited
Elemental Analyzer Scale Systems Feeders Source) Moisture Online
The CB Omni analyzer for sinter Ramsey belt scale systems monitor Accurately control process material Analyzers
measures sinter feed chemistry on- steel raw material feed to crushers, feed rates. Weighbelt Feeders help Designed for harsh industrial
line and provides minute by minute, mills, screens, preparation plants, reduce material waste, maintain applications, these rugged
reliable chemical analysis data to and coal-fired power plants to help blend consistency, increase profits, instruments use patented neutron
enable control of basicity in real time. ensure precise feeding of process and meet customer specifications. backscatter, pulse mode, ion
Gain significant economic benefits materials and maintain product chamber technology to non-
for the iron ore sintering process and quality. intrusively measure the moisture
the blast furnace. content in metallurgical grade coke
and/or iron ore pellets.
Product details › Product details › Product details › Product details ›

Products for analyzing trace metals and alloying
elements

ARL iSpark Series Niton XL5 Handheld ARL easySpark ARL 9900 Explorer 4 Analyzer
Optical Emission XRF Analyzer Metal Analyzer Simultaneous- for Industrial
Spectrometer Handheld XRF Designed for small to mid- Sequential XRF Manufacturing
Obtain precise analyzers deliver accurate size foundries and metals Series Monitor the quality of
spectrochemical analysis metal and alloy analysis for processing companies, incoming material and
Drive process control
of metals for quality material verification. or as back-up instrument, finished product with
laboratory efficiencies in iron
control and production in this bench top OES improved inclusion analysis
and steel applications with
primary metals production, analyzer performs fast, and process control.
this complete laboratory
foundries, fabricators in accurate and reliable
workflow automation
the automotive, aviation elemental analysis of solid
solution.
and appliance industries, metal samples from trace to
contract laboratories and percent level.
metal recycling industries.
Product details › Product details › Product details › Product details › Product details ›

Gauging products for hot and cold rolling processes
Non-contact Non-contact metals Non-contact On-line non-contact Non-contact paint

thickness gauges thickness gauges thickness gauges contact thickness thickness gauges

for aluminum rolling for hot strip mills for cold rolling and gauges
mills process lines
RM 210 AS SIPRO Simultaneous RM 210 CM Strip Laser TX Optical RM 300 EL and

Aluminum Thickness Profile Gauge Thickness Gauge Thickness Gauge PROSIS™ Coating
Gauge Thermo Scientific non- Thermo Scientific Thermo Scientific optical Weight Gauges
Thermo Scientific non- contact thickness thickness gauges for thickness gauges provide Thermo Scientific paint
contact thickness gauges gauges for hot strip cold rolling and process accurate on-line non-contact thickness gauges provides
provide reliable, repeatable mills provide reliable, lines provide accurate, thickness measurements for fast, accurate and reliable
process control data to high-speed repeatable non-contact thickness a variety of sheet processing profile measurement of
ensure product uniformity, process control data measurement of flat sheet applications in the steel and multilayer paint and organic
and increase output. Get to identify operating steel in every type of aluminum industries. coatings, providing essential
accurate, non-contact issues, ensure product processing line. information to optimize your
thickness measurement uniformity, and increase production process.
of aluminum and aluminum output.
alloys with gauges specially
designed for aluminum cold
strip and foil mills.

Gauging products for hot and cold rolling
processes
Hot coating weight Non-contact Metals coating Basis weight Measurement and
gauges metallic coating weight gauge sensor control system

gauges
RM 310 EH Hot RM 315 EC Cold Cold Coating Weight Beta Plus Basis 21PlusHD
Coating Weight Coating Weight Gauges Weight Sensor Measurement and
Gauges Gauges Thermo Scientific coating Save raw materials, improve Control System
Thermo Scientific hot Thermo Scientific metallic weight gauges have yields, and produce higher Thermo Scientific™
coating weight gauges coating gauge provides employed the physics quality products with basis 21PlusHD allows
significantly improves fast, accurate, non- of x-ray fluorescence to weight transmission sensors manufacturers of coated
coating weight control by contact measurement provide accurate and for extrusion coating, products or extrusion
reducing the dead time of coatings applied to reliable on line measurement nonwovens, roofing and coated products to maintain
between the air knives and flat sheet products, of zinc, tin and other metallic building products. the high performance
measurement, resulting in helping to ensure coating coatings. characteristics of critical
raw material savings and a uniformity, product quality layers, such as adhesion or
reduction in scrap. and raw materials savings. barrier layers.

Improving furnace efficiency and reducing energy
consumption

PrimaPRO Process Mass Spectrometer Prima BT Bench Top Mass Spectrometer
The combination of fast, accurate MS gas analysis for gas efficiency, heat Achieve high scanning speeds and reproducible measurements with the
and mass balances and hydrogen analysis, with advanced process control Thermo Scientific Prima BT Bench Top Mass Spectrometer. Specifically
and mathematical modeling, can reduce coke consumption by up to 100 kg designed for process development laboratories, this process gas analyzer is
per ton and increase iron production. Process Mass Spectrometers provide a highly precise, multi-port magnetic sector gas analyzer.
fast, accurate, comprehensive gas analysis, enabling integrated steel mills
and mini-mills to efficiently monitor primary and secondary conversion
methods.
Product details › Product details ›

Environmental - Air quality monitoring

Ambient Gas Monitoring Continuous Emissions Monitoring Systems (CEMS)
We offer a variety of analyzers for the ambient monitoring of the criteria Comply with regulatory guidelines while meeting your own specific air quality
pollutant gases, including CO, NOX, SO2, and others such as CH4 and monitoring needs. These systems are designed to meet US EPA 40CFR
CO2. Parts 60 and 75 standards while providing unsurpassed sensitivity, accuracy
and reliability.
Product details › Product details ›

Environmental - Radiation monitoring and soil
analysis

ASM IV Series Automatic Niton XL5 Handheld XRF RadEye GR Grapple RadEye SPRD Personal
Scrap Monitoring System Analyzer Monitoring System Radiation Detector
Detect radioactive contamination in The Thermo Scientific Niton XL5 This wireless radiation detection The pocket-sized Thermo Scientific
scrap metal before it even enters Handheld XRF Analyzer enable system is designed to be installed RadEye SPRD Personal Radiation
the supply chain with an automatic to measure heavy metal in soils on a grapple to monitor scrap metal, Detector alerts workers to potential
scrap monitoring system. around currently running and former preventing radioactive contaminated radiation exposure at greater
metallurgic plants. scrap metal from making its way into distances without increasing false
the steel making process. alarms so they can respond quickly
and decisively to real radiation
threats.
Product details › Product details › Product details › Product details ›

Additional resources
White Paper Infographic Application Note Application Note Infographic

High Speed The Iron and Steel Improving Low Application of 10 Reasons (and
Archiving of Manufacturing Carbon Steel On-line Elemental Places) Recyclers
Thickness and Process Production in Analysis for Control Need Radiation
Profile Data in the Specialty Steel of Sinter Feed Detection
View this process map
Hot Strip Mill of the complete range of
Processes Basicity Contaminated scrap metal
This paper describes a technologies that improve The need for refined steel The basicity of sinter feed can result in expensive plant
stereoscopic x-ray profile each stage of the steel with greater durability and material is an important decontamination and shut
gauge with the ability to manufacturing production resistance to heat and parameter in the efficient down. Multiple points of
determine both the cross- process, from incoming raw corrosion has led to the operation of the sintering inspection are needed to
thickness profile and the materials to the final coating increased use of vacuum and iron making process. ensure processed materials
physical position of the strip line. degassing processes, are free from radiation.
in space. such as VOD and RH, in
secondary steel production.
Download › Download › Download › Download › Download ›

Additional resources
Brochure Video Video Poster Web Page

Optimize Your The Iron Ore Hot and Cold Rolling Ultra-Fast Inclusion PGNAA/PFTNA
Metals Production Sintering Process Processes in Steel Analysis with Spark- Technology
Process Manufacturing OES The CB Omni analyzer
The production of high-
Shifts in steel production quality sinter is crucial for Metal thickness and Spark OES for the analysis uses Prompt Gamma
require producers to assuring consistent, stable coating weight gauges of solid steel samples Neutron Activation Analysis
be aware of, and willing furnace productivity with provide precise, real-time allows performing various (PGNAA) or Pulsed Fast
to adopt, the latest a low consumption of measurements during high- types of inclusion related Thermal Neutron Activation
technologies to lead the reductants. speed production of steel determinations in the time of (PFTNA) to determine
industry, both commercially plate and sheet. a standard OES analysis. elemental concentration in
and environmentally. bulk materials. The method
is deeply penetrative
Download › Watch › Watch › Download › and measures through
many centimeters of
material making it an ideal
technology for real-time
elemental analysis of bulk
materials on conveyor belts.
View ›

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Demanding steel plants, pure metals producers and companies

Online PGNAA elemental analyzers are used in the sinter

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Compared to the clean raw material to which manufacturers

With product quality, process integrity, safety, and regulatory

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• Weighbelt feeders provide a consistent flow for blending or batching,

• Online elemental analyzers help monitor and control sintering process

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There are coating weight gauges to ensure coating uniformity

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Radiation detection portals & monitors

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Click here to learn more about PGNAA and PFTNA.

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The X-ray fluorescence process

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Read how OES provides

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Non-contact Non-contact metals Non-contact On-line non-contact Non-contact paint

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RM 210 AS SIPRO Simultaneous RM 210 CM Strip Laser TX Optical RM 300 EL and

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